Low pressure drop static mixing system

ABSTRACT

A contaminated gas stream can be passed through an in-line mixing device, positioned in a duct containing the contaminated gas stream, to form a turbulent contaminated gas stream. One or more of the following is true: (a) a width of the in-line mixing device is no more than about 75% of a width of the duct at the position of the in-line mixing device; (b) a height of the in-line mixing device is no more than about 75% of a height of the duct at the position of the in-line mixing device; and (c) a cross-sectional area of the mixing device normal to a direction of gas flow is no more than about 75% of a cross-sectional area of the duct at the position of the in-line mixing device. An additive can be introduced into the contaminated gas stream to cause the removal of the contaminant by a particulate control device.

REFERENCE TO RELATED APPLICATION

The present application claims the benefit of U.S. Provisional Application Ser. No. 62/084,413, filed Nov. 25, 2014, which is incorporated herein by this reference in its entirety.

Cross reference is made to U.S. patent application Ser. No. 13/951,167, filed Jul. 25, 2013, entitled “PROCESS TO ENHANCE MIXING OF DRY SORBENTS AND FLUE GAS FOR AIR POLLUTION CONTROL” (now U.S. Pat. No. 8,974,756), which is incorporated herein by this reference in its entirety.

FIELD

The disclosure relates generally to treatment of waste gas and particularly to applying additives to waste gas to remove target contaminants.

BACKGROUND

Increasingly stringent pollution control standards for acid gases and trace air toxics, including hydrochloric acid (HCl), sulfur trioxide (SO₃), and mercury (Hg), pose greater challenges for industries. Current best control practices for sorbent pollution control processes, such as activated carbon injection (ACI) and dry sorbent injection (DSI), must be improved. In many cases, a further increase in sorbent injection rate is uneconomical, ineffective, and/or otherwise adversely impacts the waste gas treatment process.

External constraints can also hamper additive or sorbent performance. The effectiveness of in-duct sorbent injection can often be limited due to constraints of duct layout, non-ideal injection locations, sorbent in-flight residence time, temperature, adverse flue gas chemistry, and close proximity to particulate control device.

Devices placed in the duct to improve additive or sorbent performance, such as in-line gas mixing devices, can cause operational issues. At periods of high load, for example when a power plant is running at or near full capacity during summer extremes, the pressure drop caused by can cause a measurable impact on plant performance and efficiency.

There is therefore a need for improved methods of sorbent/gas mixing that can be implemented in limited duct space while maintaining plant operational parameters within acceptable levels.

There is a further need for methods and systems that can achieve desired sorbent/gas mixing with lower pressure drop at high or peak load conditions.

SUMMARY

These and other needs are addressed by the various aspects, embodiments, and configurations of the present disclosure. The disclosure is directed to a method and system for enhanced removal of contaminants from coal combustion and other thermal processes, particularly the use of various mixing device configurations that can provide improved additive distribution in a contaminated gas stream and/or can reduce the pressure drop across a mixing device.

The method and system can include:

(a) a thermal unit to heat (e.g., combust) a contaminated feed material and produce a contaminated gas stream;

(b) an optional air heater to transfer thermal energy from the contaminated gas stream to air prior to introduction of the air into the thermal unit;

(c) a mixing device (typically a static mixing device) to induce turbulent flow in the contaminated gas stream;

(d) an additive injection system, positioned downstream of the mixing device, to introduce an additive into the contaminated gas stream, the additive controlling a contaminate level in a treated gas stream (e.g., at least partially removing or causing the removal of the contaminant) prior to discharge of the treated gas stream into the environment;

(e) the mixing device positioned downstream of the additive injection system to form a mixed gas stream comprising a typically substantially homogeneous distribution of the additive in the mixed gas stream; and

(f) a downstream particulate control device to remove particulates (which can include the contaminant and/or a derivative thereof) from the additive-containing gas stream and from the treated gas stream.

The additive-containing gas stream can include a substantially homogeneous distribution of the additive in the additive-containing gas stream.

The energy for mixing by the mixing device can be primarily from a loss in pressure as the contaminated gas stream flows through the mixing device.

The contaminant can include mercury, and the additive can be one or more of a halogen, halide, and powdered activated carbon.

The contaminant can include one or more of nitrogen oxides (NO_(X)), sulfur oxides (SOx), hydrochloric acid (HCl), hydrogen sulfide, and hydrofluoric acid (HF), and the additive one or more of lime, an alkaline earth metal sesquicarbonate, an alkali metal sesquicarbonate, a metal oxide, an alkaline earth metal carbonate, an alkali earth metal carbonate, an alkaline earth metal bicarbonate, and an alkali earth metal bicarbonate.

In the additive-containing gas stream, the distance from an output of the mixing device to an input of a downstream particulate control device can be at least about one times the hydraulic diameter of the pipe or duct, but is commonly no more than about ten times the hydraulic diameter.

The distance from a point of introduction of the additive into the contaminated gas stream to an input to the mixing device can be at least about one times the hydraulic diameter but is commonly no more than about ten times the hydraulic diameter.

A distance from an output of the static mixing device to a location of introduction of the additive (or in some applications from a point of introduction of the additive into the contaminated gas stream to an input to the mixing device) can be no more than about one times the hydraulic diameter of a conduit positioned between the mixing device and introduction location.

The mixing device can be a static mixing device having an arrangement of mixing elements in one or more mixing sections. The mixing elements, for instance, can be one or more of static fan-type blades, baffles, and/or plates. The mixing elements can be curved and/or helically shaped. The arrangement of mixing elements commonly includes from about 1 to about 5 static, or substantially stationary and/or fixed, mixing elements but can include from about 2 to about 25 mixing elements.

The flue gas velocity of the contaminated gas stream commonly ranges from about 5 to about 50 m/s.

The additive-containing gas stream can have substantially turbulent flow, and the mixing device can simultaneously cause flow division and radial mixing in the additive-containing gas stream.

A number of differing process configurations are possible.

The additive, whether an acid gas controlling, mercury capture additive, flue gas conditioning agent, or other additive, may be added downstream of the mixing device or mixing system.

The additive, whether an acid gas controlling or mercury capture additive, can be introduced into the contaminated gas stream downstream of an air heater, and the mixing device can be positioned downstream of both the air heater and the point of introduction of the additive.

The acid gas controlling additive can be an alkaline sorbent, and the alkaline sorbent and/or a mercury capture sorbent can be introduced into the contaminated gas stream downstream of the mixing device.

The alkaline sorbent can be introduced into the contaminated gas stream downstream of a first particulate control device and upstream of a second particulate control device.

The additive can be introduced into the contaminated gas stream upstream of an air heater.

The static mixing device can be positioned upstream of the air heater.

The additive can be an alkaline sorbent, and the alkaline sorbent and/or a mercury capture sorbent can be introduced into the contaminated gas stream downstream of the mixing device and air heater.

The mixing device can be positioned downstream of the air heater.

The additive can be an alkaline sorbent, and the alkaline sorbent and/or a mercury capture sorbent can be introduced into the contaminated gas stream downstream of the mixing device and air heater.

The additive can include both an alkaline sorbent and a mercury capture sorbent, and both the alkaline and mercury capture sorbents can be introduced into the contaminated gas stream upstream of the mixing device.

A mixing system can comprise a plurality of mixing devices. The plurality of mixing devices may be organized in an array. Typically, the array contains rows and columns. Rows or columns of mixing devices in an array may be rotated about an axis. Such rotation may reduce the operational cross sectional area (or cross-sectional area of the mixing device normal to the direction of gas flow) of the mixing devices relative to the cross sectional area of the pipe or duct (normal to the direction of gas flow).

An array of mixing devices can comprise rotatable mixing elements. The mixing elements may be adjusted individually, or they may be part of a rotating axis that runs through a row or column of mixing devices.

A method and system can include:

a thermal unit to heat (e.g., combust) a contaminated feed material and produce a contaminated gas stream;

an optional air heater to transfer thermal energy from the contaminated gas stream to air prior to introduction of the air into the thermal unit;

an in-line mixing device to induce turbulent flow in the contaminated gas stream, with one or more of the following being true:

-   -   (a) a width of the in-line mixing device is no more than about         75% of a width of the duct at the position of the in-line mixing         device;     -   (b) a height of the in-line mixing device is no more than about         75% of a height of the duct at the position of the in-line         mixing device; and     -   (c) a cross-sectional area of the mixing device normal to a         direction of gas flow is no more than about 75% of a         cross-sectional area of the duct at the position of the in-line         mixing device;

an additive injection system, positioned upstream or downstream of the in-line mixing device, to introduce an additive (e.g., a solid, liquid, or gas) into the contaminated gas stream, the additive controlling a contaminate level in a treated gas stream prior to discharge of the treated gas stream into the environment, the additive-containing gas stream comprising a substantially homogeneous distribution of the additive in the additive-containing gas stream; and a downstream particulate control device to remove particulates from the additive-containing gas stream and form the treated gas stream.

The in-line mixing device can be a static or dynamic mixing device and can cover only part of the cross section of a duct or pipe. For example, the mixing device can cover less than 50%, or less than 25%, of the cross section of the duct.

When the additive is injected downstream of the mixing device, the mixing device can create a turbulent zone that induces mixing of the additive in the gas stream even though the mixing device covers only part of the duct.

A gas treatment system and method can include:

a thermal unit to heat (e.g., combust) a contaminated feed material and produce a contaminated gas stream; and

a mixing device positioned in a conduit for transporting the contaminated gas stream, wherein, in a first operating mode, the mixing device and/or a member thereof has a first position relative to a direction of flow of the contaminated gas stream and, in a second operating mode, the mixing device and/or a member thereof has a different second position relative to the direction of flow of the contaminated gas stream.

One or more of the following can be true:

-   -   (a) the first operating mode provides a first pressure drop of         the contaminated gas stream passing the mixing device and the         second operating mode provides a second pressure drop of the         contaminated gas stream passing the mixing device, the first         pressure drop being greater than the second pressure drop;     -   (b) the first operating mode provides a first level of turbulent         flow of the contaminated gas stream passing the mixing device         and the second operating mode provides a second level of         turbulent flow of the contaminated gas stream passing the mixing         device, the first level of turbulent flow being greater than the         second level of turbulent flow;     -   (c) in the first operating mode, a plane of a face of the mixing         device has a first angular orientation relative to a direction         of flow of the contaminated gas stream and in the second         operating mode the plane of the face of the mixing device has a         second angular orientation relative to the direction of flow of         the contaminated gas stream, the first and second angular         orientations being different; and     -   (d) in the first operating mode and during a selected time         interval, a first amount of the contaminated gas stream passes         through the mixing device and, in the second operating mode and         during the selected time interval, a second amount of the         contaminated gas stream passes through the mixing device, the         first amount being greater than the second amount.

A computer-controlled feedback system can be utilized to determine when the mixing devices, or the mixing elements, should be moved from the first to the second orientations and vice versa.

The control system can include:

a microprocessor;

a computer readable medium coupled to the microprocessor;

a sensor to sense a stimulus; and

a mixing device positioned in a contaminated gas stream.

The microprocessor, in response to receiving a sensed stimulus indicating an occurrence of a selected event (e.g., a selected, determined, or predetermined current power load, pressure drop, sorbent consumption, and/or sensed contaminant concentration), can change a position and/or orientation of the mixing device and/or a member thereof relative to a direction of flow of the contaminated gas stream from a first position and/or orientation to a second position and/or orientation to change one or more of the above parameters (a)-(d) of the contaminated gas stream passing the mixing device.

The computer-controlled feedback system may be connected to a mechanical actuating system that rotates the static mixing devices or mixing elements.

The present disclosure can provide a number of advantages depending on the particular configuration. The disclosed process and system can couple a primary sorbent injection process with an upstream or downstream stationary static gas mixing device having a high degree of mixing effectiveness to achieve a more uniform particle distribution, to eliminate substantially stratification, such as from a vertical temperature gradient, or cause destratification in the gas stream, and to improve contact between gas and sorbent. Typical applications are gas/gas mixing such as ammonia distribution in a Selective Catalytic Reduction or SCR unit. However, in the method and system, the same or similar mixing device geometry can achieve substantially uniform particle mixing with gas over a shorter, and often the shortest possible, path. The substantially uniform particle mixing can enhance mass transfer of trace pollutants to the sorbent with a minimal impact on system pressure drop. The disclosed process and system can provide reduced sized mixing devices to reduce pressure drop in the gas stream. The disclosed process and system can, for example, provide reduced pressure drop by alternating a position and/or orientation of the mixing device(s) relative to a direction of gas stream flow. The disclosed process and system can provide a control-feedback computational system that varies the pressure drop in response to one or more sensed stimuli.

These and other advantages will be apparent from the disclosure of the aspects, embodiments, and configurations contained herein.

“A” or “an” entity refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein. It is also to be noted that the terms “comprising”, “including”, and “having” can be used interchangeably.

“Absorption” is the incorporation of a substance in one state into another of a different state (e.g. liquids being absorbed by a solid or gases being absorbed by a liquid). Absorption is a physical or chemical phenomenon or a process in which atoms, molecules, or ions enter some bulk phase—gas, liquid or solid material. This is a different process from adsorption, since molecules undergoing absorption are taken up by the volume, not by the surface (as in the case for adsorption).

“Adsorption” is the adhesion of atoms, ions, biomolecules, or molecules of gas, liquid, or dissolved solids to a surface. This process creates a film of the adsorbate (the molecules or atoms being accumulated) on the surface of the adsorbent. It differs from absorption, in which a fluid permeates or is dissolved by a liquid or solid. Similar to surface tension, adsorption is generally a consequence of surface energy. The exact nature of the bonding depends on the details of the species involved, but the adsorption process is generally classified as physisorption (characteristic of weak van der Waals forces) or chemisorption (characteristic of covalent bonding). It may also occur due to electrostatic attraction.

“At least one”, “one or more”, and “and/or” are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C”, “one or more of A, B, or C” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together. When each one of A, B, and C in the above expressions refers to an element, such as X, Y, and Z, or class of elements, such as X₁-X_(n), Y₁-Y_(m), and Z₁-Z_(o), the phrase is intended to refer to a single element selected from X, Y, and Z, a combination of elements selected from the same class (e.g., X₁ and X₂) as well as a combination of elements selected from two or more classes (e.g., Y₁ and Z_(o)).

The term “automatic” and variations thereof, as used herein, refers to any process or operation, which is typically continuous or semi-continuous, done without material human input when the process or operation is performed. However, a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be “material”.

“Biomass” refers to biological matter from living or recently living organisms. Examples of biomass include, without limitation, wood, waste, (hydrogen) gas, seaweed, algae, and alcohol fuels. Biomass can be plant matter grown to generate electricity or heat. Biomass also includes, without limitation, plant or animal matter used for production of fibers or chemicals. Biomass further includes, without limitation, biodegradable wastes that can be burnt as fuel but generally excludes organic materials, such as fossil fuels, which have been transformed by geologic processes into substances such as coal or petroleum. Industrial biomass can be grown from numerous types of plants, including miscanthus, switchgrass, hemp, corn, poplar, willow, sorghum, sugarcane, and a variety of tree species, ranging from eucalyptus to oil palm (or palm oil).

“Coal” refers to a combustible material formed from prehistoric plant life. Coal includes, without limitation, peat, lignite, sub-bituminous coal, bituminous coal, steam coal, waste coal, anthracite, and graphite. Chemically, coal is a macromolecular network comprised of groups of polynuclear aromatic rings, to which are attached subordinate rings connected by oxygen, sulfur, and aliphatic bridges.

The term “computer-readable medium” as used herein refers to any computer-readable storage and/or transmission medium that participate in providing instructions to a processor for execution. Such a computer-readable medium can be tangible, non-transitory, and non-transient and take many forms, including but not limited to, non-volatile media, volatile media, and transmission media and includes without limitation random access memory (“RAM”), read only memory (“ROM”), and the like. Non-volatile media includes, for example, NVRAM, or magnetic or optical disks. Volatile media includes dynamic memory, such as main memory. Common forms of computer-readable media include, for example, a floppy disk (including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes, or any other magnetic medium, magneto-optical medium, a digital video disk (such as CD-ROM), any other optical medium, punch cards, paper tape, any other physical medium with patterns of holes, a RAM, a PROM, and EPROM, a FLASH-EPROM, a solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read. A digital file attachment to e-mail or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. When the computer-readable media is configured as a database, it is to be understood that the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art-recognized equivalents and successor media, in which the software implementations of the present disclosure are stored. Computer-readable storage medium commonly excludes transient storage media, particularly electrical, magnetic, electromagnetic, optical, magneto-optical signals.

A “computer readable storage medium” may be, for example, but not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus, or device, or any suitable combination of the foregoing. More specific examples (a non-exhaustive list) of the computer readable storage medium would include the following: an electrical connection having one or more wires, a portable computer diskette, a hard disk, a random access memory (RAM), a read-only memory (ROM), an erasable programmable read-only memory (EPROM or Flash memory), an optical fiber, a portable compact disc read-only memory (CD-ROM), an optical storage device, a magnetic storage device, or any suitable combination of the foregoing. In the context of this document, a computer readable storage medium may be any tangible medium that can contain, or store a program for use by or in connection with an instruction execution system, apparatus, or device.

A computer readable signal medium may be any computer readable medium that is not a computer readable storage medium and that can communicate, propagate, or transport a program for use by or in connection with an instruction execution system, apparatus, or device. A computer readable signal medium may convey a propagated data signal with computer readable program code embodied therein, for example, in baseband or as part of a carrier wave. Such a propagated signal may take any of a variety of forms, including, but not limited to, electro-magnetic, optical, or any suitable combination thereof. Program code embodied on a computer readable signal medium may be transmitted using any appropriate medium, including but not limited to wireless, wireline, optical fiber cable, RF, etc., or any suitable combination of the foregoing.

The terms “determine”, “calculate” and “compute,” and variations thereof, as used herein, are used interchangeably and include any type of methodology, process, mathematical operation or technique.

A “dynamic mixer” or “dynamic mixing device” is a device for the continuous or substantially continuous mixing of fluid materials. Dynamic mixers can be used to mix liquid and/or gas streams, disperse gas into liquid, or blend immiscible liquids. The energy needed for mixing comes primarily from movement of mixing elements in the dynamic mixer. Typical construction materials for dynamic mixer components include stainless steel, polypropylene, Teflon™, polyvinylidene fluoride (“PVDF”), polyvinyl chloride (“PVC”), chlorinated polyvinyl chloride (“CPVC”) and polyacetal.

“High alkali coals” refer to coals having a total alkali (e.g., calcium) content of at least about 20 wt. % (dry basis of the ash), typically expressed as CaO, while “low alkali coals” refer to coals having a total alkali content of less than 20 wt. % and more typically less than about 15 wt. % alkali (dry basis of the ash), typically expressed as CaO.

“High iron coals” refer to coals having a total iron content of at least about 10 wt. % (dry basis of the ash), typically expressed as Fe₂O₃, while “low iron coals” refer to coals having a total iron content of less than about 10 wt. % (dry basis of the ash), typically expressed as Fe₂O₃. As will be appreciated, iron and sulfur are typically present in coal in the form of ferrous or ferric carbonates and/or sulfides, such as iron pyrite.

“High sulfur coals” refer to coals having a total sulfur content of at least about 3 wt. % (dry basis of the coal) while “medium sulfur coals” refer to coals having between about 1.5 and 3 wt. % (dry basis of the coal) and “low sulfur coals” refer to coals having a total sulfur content of less than about 1.5 wt. % (dry basis of the coal).

The “hydraulic diameter” is a commonly used term when handling flow in noncircular tubes and channels. The hydraulic diameter is defined as four times the cross-sectional area of the channel divided by the inside perimeter of the channel.

“Laminar flow” (or streamline flow) occurs when a fluid flows in substantially parallel layers, with little or no disruption between the layers. At low flow velocities, the fluid tends to flow without lateral mixing, and adjacent layers slide past one another like playing cards. There are commonly no cross currents perpendicular to the direction of flow, nor eddies or swirls of fluids. In laminar flow, the motion of the particles of fluid is very orderly with all particles moving in straight lines parallel to the pipe walls. In fluid dynamics, laminar flow is a flow regime characterized by high momentum diffusion and low momentum convection. When a fluid is flowing through a closed channel such as a pipe or between two flat plates, either of two types of flow may occur depending on the velocity of the fluid: laminar flow or turbulent flow. Laminar flow tends to occur at lower velocities, below the onset of turbulent flow.

“Lime” refers to a caustic alkaline earth metal substance, such as calcium hydroxide (Ca(OH)₂), calcium oxide, and mixtures thereof produced by heating limestone.

A “load profile” refers to a graph of the variation in the electrical load versus time. A load profile will generally vary according to customer type (typical examples include residential, commercial and industrial), temperature and holiday seasons. Power producers use this information to plan how much electricity they will need to make available at any given time. Load profiles are typically determined by direct metering and/or inferred from customer billing or other data. In a load research calculation, a utility uses a transformer's maximum demand reading and accounting for the known number of each customer type supplied by the transformers. Actual demand can be collected at strategic locations to perform more detailed load analysis, which can be beneficial to both distribution and end-user customers looking for peak consumption. Smart grid meters, utility meter load profilers, data logging sub-meters and portable data loggers accomplish this task by recording readings at a set interval.

“Particulate” refers to fine particles, such as fly ash, unburned carbon, contaminate-carrying powdered activated carbon, soot, byproducts of contaminant removal, excess solid additives, and other fine process solids, typically entrained in a mercury-containing gas stream.

“Means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112, Paragraph 6. Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials or acts and the equivalents thereof shall include all those described in the summary of the disclosure, brief description of the drawings, detailed description, abstract, and claims themselves.

The term “module” as used herein refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that is capable of performing the functionality associated with that element.

“Pressure drop” refers to the difference in pressure between two points of a fluid carrying network. Pressure drop occurs when frictional forces, caused by the resistance to flow, act on a fluid as it flows through the tube. Pressure drop is determined by measuring the absolute or gauge pressure at the two points and determining the difference. Alternatively, differential pressure can be directly measured for the two points. Devices used to measure pressure include pressure gauges and manometers. Examples of pressure gauges include hydrostatic pressure gauges, piston-type gauges, liquid columns (using the pressure head equation), McLeod gauges, aneroid gauges (e.g., Bourdon pressure gauges, diaphragm gauges, and bellows gauges), magnetic coupling gauges, spinning rotor gauges, electronic pressure sensors, thermal conductivity gauges, Pirani gauges, two-wire gauges, ionization gauges (e.g., hot cathode gauges and cold cathod gauges), and the like.

“Separating” and cognates thereof refer to setting apart, keeping apart, sorting, removing from a mixture or combination, or isolating. In the context of gas mixtures, separating can be done by many techniques, including electrostatic precipitators, baghouses, scrubbers, and heat exchange surfaces.

A “sorbent” is a material that sorbs another substance; that is, the material has the capacity or tendency to take it up by sorption.

“Sorb” and cognates thereof mean to take up a liquid or a gas by sorption.

“Sorption” and cognates thereof refer to adsorption and absorption, while desorption is the reverse of adsorption.

A “static mixer” or “static mixing device” is a device for the continuous or substantially continuous mixing of fluid materials. Static mixers can be used to mix liquid and/or gas streams, disperse gas into liquid, or blend immiscible liquids. The energy needed for mixing comes primarily from a loss in pressure as fluids flow through the static mixer. One common design of static mixer is the plate-type mixer. Another common design includes mixer elements contained in a cylindrical (tube) or squared housing. Typical construction materials for static mixer components include stainless steel, polypropylene, Teflon™, polyvinylidene fluoride (“PVDF”), polyvinyl chloride (“PVC”), chlorinated polyvinyl chloride (“CPVC”) and polyacetal.

“Turbulent flow” is a less orderly flow regime that is characterized by eddies or small packets of fluid particles which result in lateral mixing.

Unless otherwise noted, all component or composition levels are in reference to the active portion of that component or composition and are exclusive of impurities, for example, residual solvents or by-products, which may be present in commercially available sources of such components or compositions.

All percentages and ratios are calculated by total composition weight, unless indicated otherwise.

It should be understood that every maximum numerical limitation given throughout this disclosure is deemed to include each and every lower numerical limitation as an alternative, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this disclosure is deemed to include each and every higher numerical limitation as an alternative, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this disclosure is deemed to include each and every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein. By way of example, the phrase from about 2 to about 4 includes the whole number and/or integer ranges from about 2 to about 3, from about 3 to about 4 and each possible range based on real (e.g., irrational and/or rational) numbers, such as from about 2.1 to about 4.9, from about 2.1 to about 3.4, and so on.

The preceding is a simplified summary of the disclosure to provide an understanding of some aspects of the disclosure. This summary is neither an extensive nor exhaustive overview of the disclosure and its various aspects, embodiments, and configurations. It is intended neither to identify key or critical elements of the disclosure nor to delineate the scope of the disclosure but to present selected concepts of the disclosure in a simplified form as an introduction to the more detailed description presented below. As will be appreciated, other aspects, embodiments, and configurations of the disclosure are possible utilizing, alone or in combination, one or more of the features set forth above or described in detail below.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings are incorporated into and form a part of the specification to illustrate several examples of the present disclosure. These drawings, together with the description, explain the principles of the disclosure. The drawings simply illustrate preferred and alternative examples of how the disclosure can be made and used and are not to be construed as limiting the disclosure to only the illustrated and described examples. Further features and advantages will become apparent from the following, more detailed, description of the various aspects, embodiments, and configurations of the disclosure, as illustrated by the drawings referenced below.

FIG. 1 is a block diagram according to a first embodiment of the disclosure;

FIG. 2 is a block diagram according to another embodiment;

FIG. 3 is a block diagram according to another embodiment;

FIG. 4 is a block diagram according to another embodiment;

FIG. 5 is a block diagram according to another embodiment;

FIG. 6 is a block diagram according to yet another embodiment;

FIG. 7 is a block diagram according to yet another embodiment;

FIG. 8 is a block diagram according to yet another embodiment;

FIG. 9 is a block diagram according to yet another embodiment;

FIG. 10 is a block diagram according to yet another embodiment;

FIG. 11 is a block diagram according to yet another embodiment;

FIG. 12 is a prior art depiction of the dependency of flow division in a static mixing device to the number of baffles or mixing elements in the static mixing device;

FIGS. 13A and 13B are a prior art depiction of how flow division and radial mixing can occur in a static mixing device;

FIG. 14 is a block diagram of according to an embodiment;

FIGS. 15A and 15B depict an in-line mixing device in front and side views according to an embodiment;

FIGS. 16A and 16B depict an in-line mixing device in front views according to an embodiment;

FIG. 17 depicts control logic for an in-line mixing device having multiple operating modes according to an embodiment;

FIG. 18A and 18B are renderings of a movable in-line mixing device according to an embodiment;

FIG. 19A and 19B are renderings of a movable in-line mixing device according to an embodiment;

FIG. 20A and 20B are renderings of a movable in-line mixing device according to an embodiment;

FIG. 21A and 21B are renderings of a movable in-line mixing device according to an embodiment;

FIGS. 22A and 22B depict a movable in-line mixing device in front views according to an embodiment;

FIGS. 23A and 23B depict a movable in-line mixing device in front views according to an embodiment; and

FIG. 24 is a block diagram of a mixing device control system according to an embodiment.

It should be understood that the diagrams are provided for example purposes only, and should not be read as limiting the scope of the disclosure. Many other configurations, including multiple sorbent injection points and/or use of multiple static mixers, are fully contemplated and included in the scope of the disclosure.

DETAILED DESCRIPTION Overview

The current disclosure is directed to an additive introduction system to introduce one or more liquid and/or solid additives to control contaminant emissions from contaminant evolving facilities, such as smelters, autoclaves, roasters, steel foundries, steel mills, cement kilns, power plants, waste incinerators, boilers, and other contaminated gas stream producing industrial facilities. Although any contaminant may be targeted by the additive introduction system, typical contaminants include one or more of acid gases (e.g., sulfur-containing compounds (such as sulfur dioxide and trioxide produced by thermal oxidation of sulfides), nitrogen oxides (such as nitrogen monoxide and dioxide), hydrogen sulfide (H₂S), hydrochloric acid (HCl), and hydrofluoric acid (HF)), mercury (elemental and/or oxidized forms), carbon oxides (such as carbon monoxide and dioxide), halogens and halides, particulates (e.g., fly ash particles and other types of unburned carbon), and the like. Although the contaminant is typically evolved by combustion, it may be evolved by other oxidizing reactions, reducing reactions, and other thermal processes such as roasting, pyrolysis, and autoclaving, that expose contaminated materials to elevated temperatures.

Static Mixing Device

FIG. 14 depicts a contaminated gas stream treatment process 1404 for an industrial facility according to an embodiment. Referring to FIG. 14, a contaminated feed material 1408 is provided. In one application, the feed material 1408 is combustible and can be any synthetic or natural, contaminate-containing, combustible, and carbon-containing material, including coal, petroleum coke, and biomass. The feed material 1408 can be a high alkali, high iron, and/or high sulfur coal. In other applications, the present disclosure is applicable to noncombustible, contaminant-containing feed materials, including, without limitation, metal-containing ores, concentrates, and tailings.

The feed material 1408 is heated in thermal unit 1400 to produce a contaminated gas stream 1412. The thermal unit 104 can be any heating device, including, without limitation, a dry or wet bottom furnace (e.g., a blast furnace, puddling furnace, reverberatory furnace, Bessemer converter, open hearth furnace, basic oxygen furnace, cyclone furnace, stoker boiler, cupola furnace, a fluidized bed furnace, arch furnace, and other types of furnaces), boiler, incinerator (e.g., moving grate, fixed grate, rotary-kiln, or fluidized or fixed bed, incinerators), calciners including multi-hearth, suspension or fluidized bed roasters, intermittent or continuous kiln (e.g., ceramic kiln, intermittent or continuous wood-drying kiln, anagama kiln, bottle kiln, rotary kiln, catenary arch kiln, Feller kiln, noborigama kiln, or top hat kiln), or oven.

The contaminated gas stream 1412 generally includes a number of contaminants. A common contaminated gas stream 108 includes mercury, particulates (such as fly ash), sulfur oxides, nitrogen oxides, hydrochloric acid (HCl), other acid gases, carbon oxides, and unburned carbon.

The contaminated gas stream 1412 is optionally passed through the (pre)heater 200 to transfer some of the thermal energy of the contaminated gas stream 1412 to air 1416 prior to input to the thermal unit 1400. The heat transfer produces a common temperature drop in the contaminated gas stream 1420 of from about 500° C. to about 300° C. to produce a cooled contaminated gas stream 1420 temperature commonly ranging from about 100 to about 400° C.

The cooled contaminated gas stream 1420 next passes into the additive injection system 1424, which injects an additive, such as a sorbent, into the cooled contaminated gas stream 1420, to form an additive-containing gas stream 1428. The additive injection system 1424 can be any suitable liquid or solid additive injection system including that described in copending U.S. application Ser. No. 13/045,076, filed Mar. 10, 2011, and Ser. No. 13/645,138, filed Oct. 4, 2012, each of which are incorporated fully herein by this reference. Other examples include spray dry and dry injection systems optionally using one or more lances, compressors or pumps, educators, etc. Commonly, the additive is injected through an array of lances positioned upstream of a particulate control device, typically an electrostatic precipitator or fabric filter.

The additive controls emissions of the selected or targeted contaminant in a treated gas stream 1432. Typically, the additive 1436 is entrained in a carrier fluid, such as a carrier liquid or gas, when introduced by additive introduction system 1424. To entrain the additive particles effectively, the additive particles typically have a mean, median, and P₉₀ size of no more than about 100 microns and even more typically ranging from about 2 to about 50 microns. The additive-containing fluid (which is mixture of the entrained additive particles and carrier gas) typically includes from about 0.10 to about 6.0 lbm material to lbm air (at standard temperature and pressure).

The additive 1436 employed depends on the contaminant targeted and can be in any form before and after injection, whether a liquid, a solid, or semi-solid. By way of example, an acid gas controlling sorbent can include an alkaline material, such as (hydrated) lime or an alkaline earth or alkali metal bicarbonate, to control emissions of nitrogen oxides (NO_(X)), sulfur oxides (SOx), hydrochloric acid (HCl), and/or hydrofluoric acid (HF) and an alkaline or alkali metal (e.g., sodium) sesquicarbonate (e.g., trona) to control emissions of sulfur oxides (SOx), hydrogen sulfide (H₂S), hydrochloric acid (HCl), and/or hydrofluoric acid (HF). Other acid gas controlling sorbents include metal oxides, such as magnesium oxide or magnesium hydroxide, alkaline earth and alkali metal carbonates, such as sodium carbonate (“soda ash”), and alkaline earth and alkali metal bicarbonates. The byproduct of the reaction between the acid gas controlling sorbent and acid gas is typically a particulate that is removed by a particulate control device. A mercury capture sorbent 400 can include halogens and/or halides. As will be appreciated, halogens and halides can oxidize elemental mercury and the resulting oxidized mercury can be collected on a particulate and/or powdered activated carbon (“PAC”) for subsequent removal by a particulate control device. Another mercury capture sorbent 400 is PAC, which can control not only mercury but also a variety of other contaminants, such as gaseous heavy metals dioxins, furans, and hydrocarbons, and which itself is removed as a particulate by a particulate control device. Often, the additive includes both acid gas controlling and mercury capture sorbents. The presence of acid gases can interfere with mercury sorption on carbon-based mercury sorbents. As will be appreciated, other additives may be used depending on the contaminant(s) targeted.

In other examples, the additive 1436 can be one or more flue gas conditioning agent(s), such as compounds comprising one or more nitrates and nitrites. Exemplary flue gas conditioning agents include those in U.S. Pat. No. 6,001,152; U.S. Pat. No. 5,833,736; U.S. Pat. No. 5,893,649; U.S. Pat. No. 5,855,649; U.S. Pat. No. 6,267,802; and U.S. Pat. No. 6,797,035, each of which is incorporated herein by reference in their entireties.

Although the carrier fluid for the additive can be any substantially (chemically) inert fluid (relative to the additive), a common carrier gas is water or air. Typically, the carrier fluid includes a minor amount, more typically no more than about 400 ppm_(v), and even more typically no more than about 390 ppm_(v) of an additive reactive component, such as carbon dioxide, that reacts with the additive. For example, carbon dioxide reacts with lime to produce calcium carbonate.

The distribution of sorbent is typically non-ideal (non-uniform) in the additive-containing gas stream. An increase in lance coverage of the additive injection system or additional additive injection often fails to provide a more uniform distribution due to mass transfer limitations. For such situations, a fixed (static) gas mixing device installed upstream or downstream of additive injection can improve particle distribution without requiring long duct runs and higher plant capital costs. In particular, the mixing device is typically located immediately upstream of the additive injection for a liquid additive as the liquid additive can deposit on the mixing device, thereby adversely hindering its performance over time in the absence of cleaning For a solid additive, the mixing device can be located not only immediately upstream but also downstream of the additive injection system.

In the latter plant configuration, the additive-containing gas stream 1428 passes a static mixing device 300, which causes additive mixing in the gas stream, thereby providing a mixed gas stream 1440 having, compared to the additive-containing gas stream 1428, an increased uniformity through the gas stream not only of additive distribution but also of temperature and/or velocity profile. This can be true for either single-phase or multiphase gas streams. As will be appreciated, a single-phase gas flow contains multiple gases while a multiphase flow contains at least one gas and at least one particulate solid, typically a sorbent additive. While FIG. 14 is discussed with reference to a dry additive only and downstream mixing, it is to be understood that the discussion of FIG. 14 applies equally to a liquid or dry additive injection immediately upstream or downstream of a mixing device.

There are a variety of static mixing devices 300 designed to achieve better gas mixing, temperature de-stratification, and more uniform velocity profile with minimal pressure drop. The static mixing device 300, for example, can be an arrangement of stationary, fixed, and/or static fan-type blades (or mixing elements) that induce turbulence and encourage mixing in the gas stream. The static mixing device 300 can be a plurality of stationary, fixed, and/or static baffles or plates (or mixing elements) on the interior wall of a duct that extend into the duct. The baffles may be straight or curved and may be offset in the flow direction or in plane. Of course, the static mixing device also may be a combination of these embodiments or any other design that would encourage mixing in the gas stream.

An example of a static mixing device 300 is the Series IV Air Blender™ or Blender Box™ manufactured by Blender Products, Inc. This static mixing device 300 is described in U.S. Pat. No. 6,595,848, which is incorporated herein by this reference. As described in U.S. Pat. No. 6,595,848, the static mixing device has multiple radially extending vanes (or mixing elements) diverging away from a center of an enclosure and terminating at outer distal ends of the vanes positioned adjacent to the enclosure. The vanes can have an inner section traversing a first distance from the center and an outer section connected to the inner section along a leading radial edge of the vane. The outer section traverses a remaining distance from the inner section to the enclosure. The inner section curves rearwardly in a first direction away from the leading radial edge, and the outer section curves rearwardly in a second direction away from the leading radial edge.

The static mixing device 300 typically is a housed-elements design in which the static mixing device elements include a series of stationary, fixed, rigid, and/or static mixing elements made of metal, ceramic, and/or a variety of materials stable at the temperature of the contaminated gas stream. Similarly, the mixing device housing, which is commonly the duct for transporting the contaminated waste gas, can be made of the same materials. Two streams of fluids, namely the contaminated gas stream and the injected sorbent stream are introduced into the static mixing device 300. As the streams move through the mixing device, the non-moving or stationary mixing elements continuously blend the components of the streams to form a mixed gas stream having a substantially homogeneous composition. Complete mixing commonly depends on many variables including the fluids' properties, tube inner diameter, number of elements and their design.

The mixing elements, particularly when helically-shaped, can simultaneously produce patterns of flow division and radial mixing. With reference to FIGS. 13A and 13B, the static mixing device 300 can effect flow division and/or radial mixing. With respect to FIG. 13A, flow division can occur in the mixed gas stream. In laminar flow, a gas stream 1300 can divide, as shown by the gas flow arrows, at the leading edge of each mixing element 1304 of the mixing device 300 and follow the channels created by the mixing element 1304 shape (which is curved or arcuate in FIG. 13A). With respect to FIG. 13B, radial mixing can, alternatively or additionally, occur in the mixed gas stream. In either turbulent flow or laminar flow, rotational circulation 1308 of the gas stream around its hydraulic center in each channel of the mixing device can cause radial mixing of the gas stream. The gas stream is commonly intermixed to reduce or eliminate radial gradients in temperature, velocity and/or gas stream composition. In most applications, the gas stream will have non-laminar or turbulent flow.

With reference to FIG. 12, flow division in a static mixing device using baffles as mixing elements is a function of the number of mixing elements in the mixing device. At each succeeding mixing element 1304, the two channels can be further divided, resulting in an exponential increase in stratification. The number of striations normally produced is 2^(n) where ‘n’ is the number of mixing elements 1304 in the mixing device. As shown by FIG. 12, the number of flow striations is two for one mixing element, four for two mixing elements, eight for three mixing elements, sixteen for four mixing elements, and thirty-two for five mixing elements. While FIGS. 12, 13A and 13B are discussed with reference to additive injection upstream of the mixing device, it is to be understood that the discussion applies equally to additive injection upstream or downstream of the mixing device.

In most applications, the additive-containing gas stream 1428, at the input to the mixing device, has laminar flow, and the number of mixing elements in the static mixing device 300 is typically at least one, more typically at least two, and even more typically ranges from about three to about fifty. Both flow division and radial mixing normally occur in power plant flue gas treatment applications. In such applications, the flue gas velocity typically ranges from about 5 to about 50 m/s and more typically from about 12 to about 20 m/s for a power plant. In other applications, the additive-containing gas stream 1428, at the input to the mixing device, has turbulent flow, and only radial mixing (and substantially no flow division) occurs.

The static mixing device 300 is typically positioned a distance upstream (or downstream) of the particulate removal device to allow adequate mixing and contaminant-additive particle interaction and a distance (upstream or) downstream of the point(s) of additive injection by the additive injection system 1424 to allow time for adequate dispersion of the additive particles in the gas stream. In the mixed gas stream, the distance from an output of the static mixing device to an input of a downstream particulate control device can be at least about one times the hydraulic diameter of the pipe or duct. While determined by the configuration of the power plant, the maximum distance from the output of the static mixing device to the input of the particulate control device is commonly no more than about ten times the hydraulic diameter. The distance from an upstream point of introduction of the additive into the contaminated gas stream to an input to the static mixing device (or from an output of the static mixing device to a downstream point of introduction of the additive into the contaminated gas stream) is typically no more than about one times the hydraulic diameter, more typically no more than about 0.75 times the hydraulic diameter, and more typically no more than about 0.50 times the hydraulic diameter. While determined by the configuration of the power plant, the minimum distance from the point of introduction of the additive into the contaminated gas stream to the downstream input (or upstream output) to the static mixing device is commonly at least about 0.1 times the hydraulic diameter.

Referring again to FIG. 14, the mixed gas stream 1440 passes through particulate control device 500 to remove most of the particulates (and targeted contaminant and/or derivatives thereof) from the mixed gas stream 1440 and form a treated gas stream 1432. The particulate control device 500 can be any suitable device, including a wet or dry electrostatic precipitator, particulate filter such as a baghouse, wet particulate scrubber, and other types of particulate removal device.

The treated gas stream 1432 is emitted, via gas discharge 1450 (e.g., stack), into the environment.

Exemplary Process Configurations

A number of exemplary configurations of the above process will now be discussed with reference to FIGS. 1-11.

FIG. 1 depicts a process in which a mercury capture sorbent is injected at an injection location upstream of the static mixing device 300. Referring to FIG. 1, a boiler 100 combusts a combustible feed material, such as coal, and generates a mercury and acid gas-containing gas stream 110. The static mixing device 300 is placed in the flow stream of the mercury and acid gas-containing gas stream 110. In this configuration, the static mixing device 300 is positioned downstream of the injection location of a sorbent 400 injected by the additive injection system (not shown). The injected sorbent 400 can be a mercury capture sorbent, such as a halogen or halogenated compound or halogen impregnated sorbent particle, such as halogenated activated carbon. The injected sorbent 400 combines with mercury in the mercury and acid gas-containing gas stream 110 and forms mercury-containing particulates. A particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates from the mercury and acid gas-containing gas stream 110. As shown by the dashed line 104, the mercury capture sorbent can also or alternatively be injected at a location downstream of the static mixing device 300.

FIG. 2 depicts a process in which an acid gas-controlling sorbent, such as an alkaline sorbent 410, is injected at an injection location upstream of the static mixing device 300. Referring to FIG. 2, the boiler 100 combusts the combustible feed material and generates the mercury and acid gas-containing gas stream 110. The static mixing device 300 is positioned in the flow stream of the mercury and acid gas-containing gas stream 110. In this configuration, the static mixing device 300 is placed downstream of the injection location of a sorbent 410 injected by the additive injection system (not shown). In one aspect of this configuration, the injected sorbent 410 is an alkaline sorbent. As noted above, the sorbent 410 can be any other acid-controlling sorbent or mixture of acid gas-controlling sorbents. The injected sorbent 410 reacts with or otherwise reduces the concentration of SO₃ or other acid gases in the mercury and acid gas-containing gas stream 110. In this configuration, carbonaceous materials in the mercury and acid gas-containing gas stream 110, such as fly ash, may combine with the mercury in the mercury and acid gas-containing gas stream 110 due to the lower concentrations of SO₃. The particulate control device 500 then removes at least some, and typically most, of the mercury containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110. As shown by the dashed line 204, the alkaline sorbent can also or alternatively be injected at a location downstream of the static mixing device 300.

FIG. 3 illustrates a process in which an acid gas-controlling sorbent, such as an alkaline sorbent 410, is injected at an injection location upstream of the static mixing device 300 and a mercury capture sorbent is injected at an injection location downstream of the static mixing device 300. Referring to FIG. 3, the boiler 100 combusts the combustible feed material and generates a mercury and acid gas-containing gas stream 110. The static mixing device 300 is placed in the flow stream of the mercury and acid gas-containing gas stream 110. In this configuration, the static mixing device 300 is placed in the mercury and acid gas-containing gas stream 110 between the injection location of a first sorbent 410 injected by the additive injection system (not shown) and the injection location of a second sorbent 400 injected by the additive injection system (not shown). In some embodiments, the first injected sorbent 410 is an alkaline sorbent to react with one or more acid gases, and the second injected sorbent 400 is a mercury capture sorbent. As noted above, the sorbent 410 can be any other acid-controlling sorbent or mixture of acid gas-controlling sorbents. The first injected sorbent 410 reacts with or otherwise reduces the concentration of SO₃ or other acid gases in the mercury and acid gas-containing gas stream. These acid gases could potentially interfere with the second injected sorbent's 400 ability to combine with or otherwise capture mercury. The second injected sorbent 400 then combines with mercury in the mercury and acid gas-containing gas stream 110 and forms mercury containing particulates. The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110. As shown by the dashed line 304, the alkaline sorbent can also or alternatively be injected at a location downstream of the static mixing device 300.

FIG. 4 depicts a process in which an acid gas-controlling sorbent, such as an alkaline sorbent 410, is injected at an injection location upstream of the static mixing device 300, a mercury capture sorbent is injected at an injection location downstream of the static mixing device 300, and an electrostatic precipitator (“ESP”) 520 is located downstream of the air heater 200 and upstream of the static mixing device 300 and the sorbent injection locations. In this embodiment, the particulate collection device is typically a TOXECON baghouse 510. Referring to FIG. 4, the boiler 100 combusts the combustible feed material and generates a mercury and acid gas-containing gas stream 110. The static mixing device 300 is placed in the flow stream of the mercury and acid gas-containing gas stream 110. In this configuration, the static mixing device 300 is placed in the mercury and acid gas-containing gas stream 110 between the location of injection by the additive injection system (not shown) of a first injected sorbent 410 and the location of injection by the additive injection system (not shown) of a second injected sorbent 400. In some embodiments, the first injected sorbent 410 is an alkaline sorbent, and the second injected sorbent 400 is a mercury capture sorbent. As noted above, the sorbent 410 can be any other acid-controlling sorbent or mixture of acid gas-controlling sorbents. The first injected sorbent 410 reacts with or otherwise reduces the concentration of SO₃ or other acid gases in the mercury and acid gas containing gas stream. The second injected sorbent 400 then combines with mercury in the mercury and acid gas-containing gas stream 110 and forms mercury-containing particulates. In one aspect of this configuration, the ESP 520 is downstream of the air heater 200 and upstream of each of the following: the injection location of the first injected sorbent 410, the static mixing device 300, and the injection location of the second injected sorbent 400. In another aspect of this configuration, alkaline sorbent and mercury containing particles are collected with a TOXECON baghouse 510. The TOXECON baghouse 510 removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110. As shown by the dashed line 404, the alkaline sorbent can also or alternatively be injected at a location downstream of the static mixing device 300.

In some embodiments, the static mixing device 300 will be utilized in combination with Dry Sorbent Injection (“DSI”)/Activated Carbon Injection (“ACI”) dual injection. In this configuration, the static mixing device 300 is placed in the mercury and acid gas-containing gas stream 110 between the location of injection by the additive injection system (not shown) of a first injected sorbent 410 and the location of injection by the additive injection system (not shown) of a second injected sorbent 400. In this configuration, the first injected sorbent 410 is an alkaline sorbent, and the second injected sorbent 400 is activated carbon. As noted above, the sorbent 410 can be any other acid-controlling sorbent or mixture of acid gas-controlling sorbents. This embodiment will allow for maximal utilization of alkaline material and reduction of acid gases such as SO₃ prior to activated carbon injection for mercury control. Ultimately, this can reduce sorbent usage for a given sorbent injection rate, thereby reducing operating costs and/or achieving maximal combined removal of acid gases and mercury. As shown by the dashed line 504, the mercury capture sorbent can also or alternatively be injected at a location downstream of the static mixing device 300.

FIGS. 5 through 11 demonstrate additional embodiments of the disclosure. These embodiments demonstrate potential configurations applying a static mixing device 300 to hot-side sorbent injection applications. As will be appreciated, “hot side” refers to a location upstream of the air (pre)heater 200. Typical contaminated gas stream temperatures upstream of the air (pre)heater 200 are at least about 300° C. and more typically range from about 350 to about 450° C. and downstream of the air (pre)heater 200 are no more than about 250° C. and more typically range from about 120 to about 200° C.

FIG. 5 shows injection of a mercury capture sorbent 400 upstream of both the static mixing device 300 and the air (pre)heater 200 (which is located downstream of the static mixing device 300). The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 6 shows injection of an acid gas controlling sorbent, such as an alkaline sorbent 410, upstream of both the static mixing device 300 and the air (pre)heater 200 (which is located downstream of the static mixing device 300). The particulate control device 500 then removes at least some, and typically most, of the particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 7 shows injection of an acid gas controlling sorbent, such as an alkaline sorbent 410, upstream of the air (pre)heater 200 and static mixing device 300 (which is also positioned upstream of the air (pre)heater 200 and of a mercury capture sorbent 400 downstream of the air (pre)heater and static mixing device 300 but upstream of the particulate control device 500. The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 8 shows injection of an acid gas controlling sorbent, such as an alkaline sorbent 410, upstream of the air (pre)heater 200 and static mixing device 300 (which is positioned downstream of the air (pre)heater 200 (or on the cold-side) and of a mercury capture sorbent 400 downstream of the air (pre)heater and static mixing device 300 but upstream of the particulate control device 500. The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 9 shows injection of an acid gas controlling sorbent, such as an alkaline sorbent 410, upstream of the air (pre)heater 200 and static mixing device 300 (which is positioned downstream of the air (pre)heater 200 (or on the cold-side) and of a mercury capture sorbent 400 downstream of the air (pre)heater 200 and upstream of the static mixing device 300 and the particulate control device 500. The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 10 shows injection of an acid gas controlling sorbent, such as an alkaline sorbent 410, upstream of both the static mixing device 300 and the air (pre)heater 200 (which is located upstream of the static mixing device 300). The particulate control device 500 then removes at least some, and typically most, of the particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

FIG. 11 shows injection of a mercury capture sorbent 400 upstream of both the static mixing device 300 and the air (pre)heater 200 (which is located upstream of the static mixing device 300). The particulate control device 500 then removes at least some, and typically most, of the mercury-containing and other particulates (such as the byproducts of acid gas removal) from the mercury and acid gas-containing gas stream 110.

With reference to FIGS. 5-11, the mercury capture sorbent 400 as shown by dashed line 504 (FIG. 5), the alkaline sorbent 410 as shown by dashed line 604 (FIG. 6), the alkaline sorbent 410 as shown by dashed line 704 (FIG. 7), the alkaline sorbent 410 as shown by dashed line 804 (FIG. 8), the alkaline sorbent 410 as shown by dashed line 904 and mercury capture sorbent 400 as shown by dashed line 908 (FIG. 9), the alkaline sorbent 410 as shown by dashed line 1004 (FIG. 10), and the mercury capture sorbent 400 as shown by dashed line 1104 (FIG. 11) can be introduced into the contaminated gas stream downstream of the static mixing device 300.

FIGS. 15A and 15B show an in-line static or dynamic (or non-static) mixing device 1500, with plural mixing elements 1520, that has a reduced size relative to the cross-sectional area of the duct 1504 such that gas flow through a substantial portion of the duct area 1512 will not pass through the mixing device 1500. As can be seen, the duct has a height H_(D) of H_(a)+H_(b) and a width W_(D) of W_(a)+W_(b) while the mixing device 1500 has a height H_(a) and a width W_(b). Typically, the mixing device height H_(a) is no more than about 75%, more typically no more than about 70%, more typically no more than about 65%, more typically no more than about 60%, more typically no more than about 55%, and even more typically no more than about 50% of the duct height H_(D). Typically, the mixing device width W_(b) is no more than about 75%, more typically no more than about 70%, more typically no more than about 65%, more typically no more than about 60%, more typically no more than about 55%, and even more typically no more than about 50% of the duct width W_(D). Typically, the cross-sectional area of the mixing device normal to a direction of gas flow 1516 is no more than about 75%, more typically no more than about 70%, more typically no more than about 65%, more typically no more than about 60%, more typically no more than about 55%, and even more typically no more than about 50% of the cross-sectional area of the duct normal to the direction of gas flow 1516. When the additive is injected by the additive injection system 1424 immediately downstream (as shown in FIG. 15B) of the mixing device 1500 with the tip 1528 of the lance 1524 being located behind (as determined by the gas flow) the mixing device 1500, the gas first flows through the mixing device, and the additive is injected by the tip 1528 of the lance 1524 into the more turbulent gas flow. As will be appreciated, laminar gas flow is typically upstream of the mixing device 1500 while non-laminar or turbulent flow is downstream of the mixing device 1500. The reduced cross-sectional area of the mixing device can induce gas stream turbulence for better additive distribution while reducing pressure drop relative to larger mixing devices.

Other configurations are possible involving downstream sorbent injection and reduced sized mixing devices, such as mixing device 1500, substituted for the mixing devices of FIGS. 1-11. As shown by the dashed line 504 of FIG. 5, the mercury capture sorbent can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300. As shown by the dashed line 604 of FIG. 6, the alkaline sorbent can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300. As shown by the dashed line 704 of FIG. 7, the alkaline sorbent can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300. As shown by the dashed line 804 of FIG. 8, the alkaline sorbent can also or alternatively be injected at a location downstream of the static mixing device 300. As shown by the dashed lines 904 and 908 of FIG. 9, the alkaline sorbent and mercury capture sorbent, respectively, can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300. As shown by the dashed line 1004 of FIG. 10, the alkaline sorbent can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300. As shown by the dashed line 1104 of FIG. 11, the mercury capture sorbent can also or alternatively be injected at a location downstream of the reduced sized static mixing device 300.

Not shown, but contemplated by the disclosure, are additional configurations utilizing hot-side injection of one or more sorbents and a hot-side ESP (or other particulate removal device), with the static mixing device 300 placed in between and upstream or downstream of the additive injection location. The static mixing device 300, whether reduced or full sized relative to the duct, may be helpful with hot-side injection applications, that is, applications where a sorbent is injected upstream of the air (pre)heater 200. While such configurations generally benefit from increased residence time and the associated improvement in sorbent distribution, the static mixing device 300 can contribute an even more complete sorbent distribution.

With any hot-side sorbent injection application, the static mixing device 300 could be placed either upstream or downstream of the air (pre)heater. Typically, the plant configuration will dictate the appropriate location. Variables include length of flow path available, requirements for distribution of the sorbent or velocity and temperature profiles, and location of the particulate control device (including hot-side or cold-side ESP).

Further contemplated is the use of a static mixing device 300 with other wet or dry sorbents (e.g., wet flue gas desulfurization additives), that were not specifically named in this disclosure, including sorbents applied to the fuel and sorbents injected into the furnace in any of a gas, liquid, or solid phase. Although the disclosure specifically targets dry sorbent (including activated carbon and DSI) injection, it is contemplated that use of a static mixing device 300 would further improve uniformity of distribution for these sorbents, as a well as offering uniformity benefits to velocity and temperature profiles of the resulting contaminated gas stream.

Variable Pressure Drop Mixing Device

Referring to FIGS. 15A and 15B, the static or dynamic mixing device 1500 can provide a variable pressure drop by moving from a first position or orientation relative to the direction of gas flow 1516 in a first operational mode to a different second position or orientation relative to the direction of gas flow 1516 in a second operational mode. The variable position can be effected by rotation (such as by a motor, hydraulic, or electromagnetic system) of the mixing device (as shown by rotational arrows 1538) about the rotating member 1534, which rotates the mixing device around a vertical axis X 1542. In the first operational mode in which a front plane 1550 of the mixing device 1500 is substantially normal to the direction of gas flow 1516, a maximum volume of gas contacts and passes through the mixing device for a selected time interval. Thus, in the first operational mode, the pressure drop of the gas induced by the mixing device and the level of turbulent flow (and degree of mixing) downstream of the mixing device 1500 are substantially maximized. In the second operational mode in which the front plane 1550 of the mixing device 1500 is substantially parallel to the direction of gas flow 1516 (not shown), a minimum volume of gas contacts and passes through the mixing device over the selected time interval (e.g., the mixing device is substantially free of contact with the gas flow). Thus, in the second operational mode, the pressure drop of the gas induced by the mixing device and the level of turbulent flow (and degree of mixing) downstream of the mixing device 1500 are substantially minimized. The angular orientation of the mixing device relative to the direction of gas flow 1516 can be varied to realize different levels of pressure drop between the maximum and minimum pressure drop in the first and second operational modes and pass different volumes of gas over the selected interval between the minimum and maximum amounts in the first and second operational modes. Likewise, the angular orientation of the mixing device 1500 relative to the direction of gas flow 1516 can be varied to realize different levels of turbulent flow (and degree of mixing) downstream of the mixing device 1500.

Referring to FIGS. 22A and 22B, another static or dynamic mixing device configuration is depicted. The mixing device 2200, as in the mixing device of FIGS. 15A and 15B, is mounted on a vertically extending rotating member 2204 and includes multiple mixing elements 2212. The mixing device 2200 occupies most of the cross-sectional area of the duct 1504 (with the direction of gas flow being into the page). The actuator 2208 rotates the mixing device 2200 from a first orientation in the first operational mode to a second orientation in the second operational mode (of FIG. 22B) in which the gas stream contacts an edge 2216 of the mixing device.

Referring to FIGS. 23A and 23B, another static or dynamic mixing device configuration is depicted. The mixing device 2300 is mounted on a horizontally extending rotating member 2304 and includes multiple mixing elements 2312. The mixing device 2300 occupies most of the cross-sectional area of the duct 1504 (with the direction of gas flow being into the page). The motor 2308 rotates the mixing device 2300 from a first orientation in the first operational mode in which the gas stream contacts a front face or plane 2316 of the mixing device to a second orientation in the second operational mode in which the gas stream contacts a side edge 2320 of the mixing device. Thus, in the first operational mode, the pressure drop of the gas induced by the mixing device and the level of turbulent flow (and degree of mixing) downstream of the mixing device 1500 are substantially maximized while, in the second operational mode, the pressure drop of the gas induced by the mixing device and the level of turbulent flow (and degree of mixing) downstream of the mixing device 1500 are substantially minimized.

FIGS. 16A and B depict another static or dynamic mixing device configuration to realize results similar to those of FIGS. 15A and 15B. The mixing device 1600 comprises plural mixing elements 1604 configured as contoured louvers or vanes mounted within a supporting frame. The mixing device typically is a housed-elements design in which the static mixing device elements include a series of mixing elements made of metal, ceramic, and/or a variety of materials stable at the temperature of the contaminated gas stream. Similarly, the mixing device housing can be made of the same materials. Each mixing element is rotatably mounted within the supporting frame on a corresponding rotating member 1608, which is in turn engaged with an actuator 1612. The actuator 1612 rotates simultaneously the mixing elements 1604 by the respective rotating member 1608 from a first orientation relative to the direction of gas flow to a different second angular orientation relative to the direction of gas flow. While maintaining the position of the mixing device supporting frame stationary, the mixing device 1500 can provide a variable pressure drop by moving the mixing elements from a first position or orientation relative to the direction of gas flow 1516 in a first operational mode to a different second position or orientation relative to the direction of gas flow 1516 in a second operational mode. In the second operational mode in which a front plane of each of the mixing elements is substantially parallel to the direction of gas flow 1516 (FIG. 16B) and the contoured surfaces of the mixing elements do not contact the gas stream, a minimum (or no) volume of gas passes through the mixing element for a selected time interval (as an edge of the mixing element contacts the gas rather than the gas mixing portion of the mixing element). Thus, in the second operational mode, the pressure drop of the gas induced by the mixing device and level of downstream turbulent flow and degree of mixing are substantially minimized. In the first operational mode in which the front plane of the mixing elements is substantially normal to the direction of gas flow 1516 (FIG. 16A) and the contoured surfaces of the mixing elements contact the gas stream, a maximum volume of gas stream contacts and passes through the mixing device over the selected time interval (as the edge of the mixing element is parallel to the direction of gas flow and the gas mixing portion of the mixing element contacts the gas stream). Thus, in the first operational mode, the pressure drop of the gas induced by the mixing device and level of downstream turbulent flow and degree of mixing are substantially maximized. The angular orientation of the mixing device relative to the direction of gas flow 1516 can be varied to realize different levels of pressure drop between the maximum and minimum pressure drops in the first and second operational modes and pass different volumes of gas, and produce different degrees of mixing, over the selected internal between the minimum and maximum amounts in the first and second operational modes.

A number of other exemplary configurations of the rotatable static mixing device system will now be discussed with reference to FIGS. 18A, 18B, 19A, 19B, 20A, 20B, 21A and 21B.

FIG. 18B shows a static mixing system 1800 comprising an array of static mixing devices 1804. The array may be organized with a plurality of static mixing devices in rows or columns. As depicted, the array comprises two columns, each containing two rigidly connected static mixing devices 1804 stacked vertically. The columns themselves rotate independently of one another. Each column contains a rotational axis 1801 that runs through the center of the column (e.g., through the center of mass of the column and/or the axis of symmetry). Each column can be rotated, clockwise, counter-clockwise, or both, about the central rotational axis 1801, such that the mixing elements 1808 of the static mixing devices 1801 will be in plane with the gas stream. In other words, the system 1800 as depicted induces turbulence in a gas stream. The columns can be turned 90 degrees such that the system 1800 will have a smaller cross section, the mixing elements will not be exposed to the gas stream, turbulence will not be induced in the gas stream, and the static mixing system will create a lower pressure drop.

FIG. 18A shows a top view of the static mixing system. A actuator linkage system 1812 is provided. The actuator linkage system 1812 turns the columns about the axis 1801. A limit switch can limit rotation between the first and second orientations. Typically, the rotation is limited to about 90 degrees rotation.

FIG. 19B shows a static mixing system 1900 comprising an array of static mixing devices. As depicted, the array comprises five columns 1904 a-e, each containing five static mixing devices 1908 a-d stacked vertically. Each static mixing device 1908 has three static mixing elements 1910 at its center. Three rotational axes 1920 run through each column of static mixing devices. The static mixing elements 1910 are attached to the rotational axes 1920, such that a static mixing element of a static mixing device is attached to the corresponding mixing element of the other static mixing devices in the same column but not to static mixing devices in other columns. As shown in FIG. 19A, the mixing elements 1910 can be rotated about the axes 1920. In operation, the mixing elements 1910 are set at an angle to the duct or pipe. When gas passes through the static mixing system, the angle of the mixing elements 1910 induces turbulence in the gas stream and causes a pressure drop. When the mixing elements 1910 are turned such that they are substantially in plane with the flow of the gas stream, the pressure drop is minimized (and turbulence is somewhat reduced).

FIG. 21A and 21B show a detail of one static mixing device 1908 with rotatable mixing elements 1910 as depicted in this embodiment. The orientation and configuration of each of the rotational mixing elements 1910 in each mixing device in each column are shown in FIG. 19B above the respective column in FIG. 19B. The orientations of the mixing elements 1910 are in positions to induce maximum turbulence in the gas stream. Rotating the mixing elements to be in plane with the direction of gas flow induces a minimum degree of gas stream turbulence and minimizes the pressure drop.

FIG. 20B shows a static mixing system 2000 comprising an array of static mixing devices 2104. As depicted, the array comprises five columns 2108 a-e, each containing five static mixing devices 2104 a-e stacked vertically. Each static mixing device 2104 has mixing elements 2112 extending radially from its center. As depicted in FIG. 20A, the mixing elements 2112 may be rotated about an axis, so as to change the angle at which the mixing element is situated with respect to the direction of flow of the gas stream.

The number of mixing devices in an N×M array depends on the application. Each of N and M typically ranges from 1 to 25, more typically from 2 to 20, more typically from 2 to 15, and more typically from 2 to 10. In an example of a 20′×20′ duct, 4′ square mixing devices can be placed in a 5×5 array to cover substantially the cross section of the duct (see FIGS. 19A-B and 20A-b). In this configuration, the mixing devices are installed in columns. For example, one column installation might be 4′ wide, and 20′ tall. The column would comprise 5 mixing devices stacked on top of each other. Four such columns would be installed to cover the full cross section of the flue duct. In this configuration, the columns might be installed such that each column can be “turned” around a pivot point. All columns can be turned (similar to vents in a car) so that the duct cross section is no longer substantially covered by mixing devices. In an example where the mixing devices are 1′ deep, when the mixing device columns are fully “open,” the duct cross section would now be substantially open and only be blocked by 5 columns, 1′ wide each. Columns could be installed as rows (horizontal installation rather than vertical). Configurations can be envisioned where the structure of the blender array remains in place, but the blades themselves are opened closed in response to a mechanical stimulus.

While the various mixing systems of FIGS. 18A, 18B, 19A, 19B, 20A, 20B, 21A, and 21B are demonstrated with vertical rotational axes passing through each column, it is to be understood that the mixing devices in the various mixing systems can be organized into rows, with each row having a horizontal rotational axis passing through its center to rotate each row horizontally rather than vertically.

The system may be controlled with a computer operated monitoring and feedback control system. A properly configured control system could measure peak load demands and open/close the mixing device array at times lower pressure drop is needed (i.e., peak load in summer time when users are running the air conditioning units). The actuator operating this configuration also may be controlled by a properly configured control system with appropriately placed sensors.

FIG. 24 depicts a computer operated monitoring and feedback control system 2400 according to an embodiment. The system 2400 includes a load profile meter 2404, other sensor(s) 2408, a sensor 2412 to determine a degree of rotation of a mixing device and/or mixing element relative to a gas flow direction, a set of mapping data structures 2416, a mixing device/element rotation system 2420, and a control system 2424.

The load profile meter 2404 determines when electricity (and corresponding output at the power plant) is in high demand or peak conditions. This can be done using a load profile that plots variation in the electrical load versus time.

The other sensor(s) 2408 can be one or more sensors to determine one or more of: the pressure drop of the mixing system, sorbent consumption levels, and/or sensed contaminant concentration in the gas stream prior to, during, or after treatment. For example, in a system utilizing activated carbon for mercury control, the static mixing devices or mixing elements can be “closed” to create a higher pressure drop (and more mixing) if sorbent consumption needs to be reduced. The same action could be taken if mercury emissions were running above target for a given quantity of sorbent consumption (closing the mixing elements, increasing pressure drop, and increasing mixing), which would lower mercury emissions for the same quantity of sorbent.

The sensor to determine degree of rotation of the mixing device/mixing element relative to gas flow direction can be any suitable sensor for determining angular displacement relative to a selected reference point. Any position sensor can be used that permits angular position measurement. It can either be an absolute position sensor or a relative one (displacement sensor). An example is a rotary encoder, also called a shaft encoder, which is an electro-mechanical device that converts the angular position or motion of a shaft or axle to an analog or digital code.

The mapping data structures 2416 are maintained in a computer readable medium and can take many forms. In one form, the mapping data structures are a two- or more dimensional lookup table that maps one or more sensed parameters, such as current power load, pressure drop, sorbent consumption, and/or sensed contaminant concentration, against angular rotation or displacement of the mixing device and/or mixing elements relative to the direction of gas flow. A second mapping table can map the angular rotation or displacement to a command to the mixing device and/or element rotation system 2420 to cause the desired level of angular displacement. As will be appreciated, the lookup table is an array that replaces runtime computation with a simpler array indexing operation. The indexing operation can be one or more of a simple lookup in an array, an associative array, or a linked list, a binary search in an array or an associative array, a trival hash function, and the like. The savings in terms of processing time can be significant, since retrieving a value from memory is often faster than undergoing an expensive computation or input/output operation. Other forms of mapping data structures can be employed depending on the application. Alternatively, the mapping data structures 2416 can be computationally determined in substantial real time, as in runtime computation.

The mixing device and/or element rotation system can be any actuator system that effects angular displacement by one or more of mechanical, electromechanical, electromagnetic, magnetic, or hydraulically actuation.

The control system 2424 handles user input and output, supervises the operation of the other system components, applies rules or policies, and issues commands to each of the components to effect desired operations. For example, the control system 2424, in response to determining, from the load profile meter, that the power plant and electrical output are in high demand or peak conditions high demand peak load condition or state, can reduce the pressure drop.

The various components are in communication with one another via a network 2428, which can be a wired or wireless local area or wide area network depending on the application.

FIG. 17 depicts the operation of the system 2400 according to an embodiment.

In step 1700, the control system 2424 detects a stimulus to change an orientation of a mixing device and/or mixing element. As noted, the stimulus can be one or more of current power load, pressure drop, sorbent consumption, and/or sensed contaminant concentration, against angular rotation or displacement of the mixing device and/or mixing elements relative to the direction of gas flow.

In optional step 1704, the control system 2424 determines a current power load if not detected as a stimulus.

In step 1708, the control system 2424, using the mapping data structures 2416, determines a desired maximum flow resistance and/or pressure drop across the mixing device and/or elements.

In step 1712, the control system 2424 determines, from the mapping data structures 2416, a degree of rotation of the mixing device and/or elements relative to a direction of gas flow to produce the desired maximum flow resistance and/or pressure drop. As noted, the pressure drop is not simply bimodal, namely a maximum and minimum value. In some applications, the mixing device and/or elements can be finely tuned to any one of various angular displacements to produce a desired pressure drop while maintaining a desired degree of turbulent flow and mixing. For example, the angular orientation of the mixing device or elements is not simply one of 0 or 90 degrees relative to a direction of gas flow but can be any angle between those endpoints.

In step 1716, the control system 2424 generates and transmits, via network 2828, a command to the rotation system 2420 to rotate the mixing device and/or elements to the desired degree of rotation or angular displacement relative to the direction of gas flow.

In optional step 1720, the control system 2424 measures the flow resistance or pressure drop by a sensor to confirm that the degree of rotation and/or desired flow resistance result is correct.

The microprocessor in the control system then returns to step 1700.

A number of variations and modifications of the disclosure can be used. It would be possible to provide for some features of the disclosure without providing others.

For example, while ESP and baghouse particulate control devices are discussed with reference to particulate removal, one or more other or alternative particulate and/or contaminant removal devices can be employed as particulate control devices, such as wet and/or dry scrubbers.

The present disclosure, in various aspects, embodiments, and configurations, includes components, methods, processes, systems and/or apparatus substantially as depicted and described herein, including various aspects, embodiments, configurations, subcombinations, and subsets thereof. Those of skill in the art will understand how to make and use the various aspects, aspects, embodiments, and configurations, after understanding the present disclosure. The present disclosure, in various aspects, embodiments, and configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and\or reducing cost of implementation.

The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more, aspects, embodiments, and configurations for the purpose of streamlining the disclosure. The features of the aspects, embodiments, and configurations of the disclosure may be combined in alternate aspects, embodiments, and configurations other than those discussed above. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed aspects, embodiments, and configurations. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.

Moreover, though the description of the disclosure has included description of one or more aspects, embodiments, or configurations and certain variations and modifications, other variations, combinations, and modifications are within the scope of the disclosure, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative aspects, embodiments, and configurations to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. 

We claim:
 1. A method, comprising: heating a contaminated feed material and produce a contaminated gas stream; passing the contaminated gas stream through an in-line mixing device, positioned in a duct containing the contaminated gas stream, to form a turbulent contaminated gas stream, wherein at least one of the following is true: (a) a width of the in-line mixing device is no more than about 75% of a width of the duct at the position of the in-line mixing device; (b) a height of the in-line mixing device is no more than about 75% of a height of the duct at the position of the in-line mixing device; and (c) a cross-sectional area of the mixing device normal to a direction of gas flow is no more than about 75% of a cross-sectional area of the duct at the position of the in-line mixing device; introducing an additive to the contaminated gas stream, the additive at least partially removing or causing the removal of the contaminant; and thereafter removing, by a particulate control device, particulates from the contaminated gas stream, wherein the particulates comprise at least some of the contaminant and/or a derivative thereof.
 2. The method of claim 1, wherein (a) is true.
 3. The method of claim 2, wherein the width of the in-line mixing device is no more than about 50% of the duct width at the in-line mixing device position.
 4. The method of claim 1, wherein (b) is true.
 5. The method of claim 4, wherein the height of the in-line mixing device is no more than about 50% of the duct height at the in-line mixing device position.
 6. The method of claim 1, wherein (c) is true.
 7. The method of claim 6, wherein the in-line static mixing device has a cross-sectional area of the in-line mixing device normal to a direction of gas flow that is no more than about 50% of a cross-sectional area of the duct at the position of the in-line mixing device.
 8. The method of claim 7, wherein the in-line static mixing device has a cross-sectional area of the in-line mixing device normal to a direction of gas flow that is no more than about 25% of a cross-sectional area of the duct at the position of the in-line mixing device and wherein a remainder of the cross-sectional area of the duct at the position of the in-line mixing device is free of any mixing elements.
 9. The method of claim 1, wherein the additive is injected upstream and/or downstream of the mixing device, wherein the mixing device is a static mixing device, wherein, in a first operational mode, the static mixing device has a first orientation to the contaminated gas stream to produce a first pressure drop of the contaminated gas stream over the static mixing device, wherein, in a second operational mode, the static mixing device has a second orientation to the contaminated gas stream to produce a second pressure drop of the contaminated gas stream over the static mixing device, and wherein the first and second orientations are different and the first and second pressure drops are different.
 10. The method of claim 1, wherein the mixing device is a dynamic mixing device and wherein the additive is a liquid additive and further comprising injecting the additive downstream of, and in the turbulent contaminated gas stream flow produced by, the in-line mixing device.
 11. A contaminated gas treatment system, comprising: a thermal unit to heat a contaminated feed material and produce a contaminated gas stream; an air heater to transfer thermal energy from the contaminated gas stream to air prior to introduction of the air into the thermal unit; an in-line mixing device to induce turbulent flow in the contaminated gas stream, wherein at least one of the following is true: (a) a width of the in-line mixing device is no more than about 75% of a width of the duct at the position of the in-line mixing device; (b) a height of the in-line mixing device is no more than about 75% of a height of the duct at the position of the in-line mixing device; and (c) a cross-sectional area of the mixing device normal to a direction of gas flow is no more than about 75% of a cross-sectional area of the duct at the position of the in-line mixing device; and an additive injection system to introduce an additive into the contaminated gas stream, the additive controlling a contaminate level in a treated gas stream prior to discharge of the treated gas stream into the environment, wherein the additive-containing gas stream comprises a substantially homogeneous distribution of the additive in the additive-containing gas stream; and a downstream particulate control device to remove particulates from the additive-containing gas stream and form the treated gas stream.
 12. The system of claim 11, wherein (a) is true.
 13. The system of claim 12, wherein the width of the in-line mixing device is no more than about 50% of the duct width at the in-line mixing device position.
 14. The system of claim 11, wherein (b) is true.
 15. The system of claim 14, wherein the height of the in-line mixing device is no more than about 50% of the duct height at the in-line mixing device position.
 16. The system of claim 11, wherein (c) is true.
 17. The system of claim 16, wherein the in-line static mixing device has a cross-sectional area of the in-line mixing device normal to a direction of gas flow that is no more than about 50% of a cross-sectional area of the duct at the position of the in-line mixing device.
 18. The system of claim 17, wherein the in-line static mixing device has a cross-sectional area of the in-line mixing device normal to a direction of gas flow that is no more than about 25% of a cross-sectional area of the duct at the position of the in-line mixing device and wherein a remainder of the cross-sectional area of the duct at the position of the in-line mixing device is free of any mixing elements.
 19. The system of claim 11, wherein the additive is injected upstream and/or downstream of the mixing device, wherein the mixing device is a static mixing device, wherein, in a first operational mode, the static mixing device has a first orientation to the contaminated gas stream to produce a first pressure drop of the contaminated gas stream over the static mixing device, wherein, in a second operational mode, the static mixing device has a second orientation to the contaminated gas stream to produce a second pressure drop of the contaminated gas stream over the static mixing device, and wherein the first and second orientations are different and the first and second pressure drops are different.
 20. The system of claim 11, wherein the additive is a liquid additive, wherein the mixing device is a dynamic mixing device, and further comprising injecting the additive downstream of, and in the turbulent contaminated gas stream flow produced by, the in-line mixing device. 